Extrusion press systems and methods

ABSTRACT

Systems, devices, and methods are described for extruding materials. In certain embodiments, one or more hollow billets are loaded onto an elongate mandrel bar and transported along the mandrel bar to a rotating die. The billets are transported through fluid clamps, which engage the mandrel bar and provide cooling fluid to the mandrel bar tip, and through mandrel grips, which engage the mandrel bar and prevent the mandrel bar from rotating. One or more press-rams advance the billets through a centering insert and into the rotating die. A quench assembly is provided at an extrusion end of the extrusion press to quench the extruded material. A programmable logic controller may be provided to control, at least in part, operations of the extrusion press system.

BACKGROUND

The properties of a material are affected by the processing used to formand shape the material. Processing includes heat treatment, deformation,and casting. Heat treatment is the process of subjecting a metal oralloy to a particular schedule of heating and cooling that causesdesirable physical or chemical changes. Deformation is the process offorcing a piece of material to change its thickness or shape, and somedeformation techniques include forging, rolling, extruding, and drawing.Casting is the pouring of melted metal into a mold so that the metalconforms to the shape of the mold when it solidifies. Heat treatment,deformation, and casting can be used in combination, and in some casesparticular alloying elements are added to influence such processing in adesirable way.

Seamless metal tubing, such as copper tubing, is typically manufacturedusing various methods such as cast-and-roll, up-casting, or extrusionprocesses. To lower the cost of manufacturing metal tubing produced byconventional extrusion and casting techniques, manufacturers increasethe size of billets used for forming the metal tubing. These billets aretypically 100 to 1,000 pounds or more. Manufacturers thus require verylarge facilities to house the specialized large-scale machinery neededto processes the billets to form metal tubing. The sheer size of theequipment, and the billets processed by the equipment, causes theextrusion process to have large start-up and maintenance costs.Furthermore, limitations of the processes, such as extruding only onebillet at a time, lead to manufacturing inefficiencies including limitson the amount of tubing produced per run and system component wearcaused by the constant start-up and shut-down of the manufacturingprocess with respect to separate runs for each billet.

SUMMARY

Disclosed herein are systems, devices, and methods for extrudingmaterials. In certain embodiments, the systems, devices, and methodsallow for continuous extrusion of a plurality of billets. Suchcontinuous extrusion allows for relatively smaller billets to be used toproduce a desired quantity of extruded material, and therefore the scaleof such continuous extrusion press systems can be smaller thanconventional extrusion processes. The systems, devices, and methodsallow for continuous seamless extrusion of the plurality of billets.

In one aspect, the systems, devices, and methods of the presentdisclosure include a method for continuously loading and extruding aplurality of billets, the method comprising loading a first billet at areceiving end of an elongate mandrel bar, transporting the first billetalong the mandrel bar and through gripping elements that secure in placeand prevent rotation of the mandrel bar, wherein at any given time atleast one gripping element is gripping the mandrel bar, and extrudingthe first billet to form an extruded material by pressing the firstbillet through a rotating die, wherein the first billet is followed byan adjacent second billet that forms a part of the extruded material.The rotating die heats the billet as the billet advances through therotating die. In certain implementations, a substantially constantpushing force is provided against the first billet in a directiontowards the rotating die. In certain implementations, the rotation speedof the rotating die may be adjusted.

In certain implementations, the method further includes transporting thefirst billet along the mandrel bar and through cooling elements thatclamp to the mandrel bar and deliver cooling fluid to the mandrel bar,wherein at any given time at least one cooling element is clamped to themandrel bar. The billet may be transported along the mandrel bar via atrack that intermittently moves depending on the position of the firstbillet relative to the gripping elements and the cooling elements. Incertain implementations, the cooling fluid is transported to a mandrelbar tip provided on a second end of the mandrel bar opposite thereceiving end, and the cooling fluid is returned to the cooling elementsafter passing through the mandrel bar tip. The mandrel bar tip may bepositioned within the rotating die prior to receiving the first billet.In certain implementations the cooling fluid is water.

In certain implementations, continuously loading the plurality ofbillets further comprises the gripping elements alternately gripping themandrel bar to allow one or more billets to pass through the grippingelements. In certain implementations, a downstream gripping elementgrips the mandrel bar and an upstream gripping element is open, and themethod includes loading the one or more billets onto the mandrel bar andpast the open upstream gripping element, closing the open upstreamgripping element, and advancing the one or more billets to thedownstream gripping element. In certain implementations, the method thenincludes opening the downstream gripping element, advancing the one ormore billets past the open downstream gripping element, and closing thedownstream gripping element.

In certain implementations, continuously loading the plurality ofbillets further comprises the cooling elements alternately clamping themandrel bar to allow one or more billets to pass through the coolingelements. In certain implementations, a downstream cooling elementclamps the mandrel bar and delivers cooling fluid to the mandrel bar,and an upstream cooling element is open, and the method includes loadingthe one or more billets onto the mandrel bar and past the open upstreamcooling element, closing the open cooling gripping element, andadvancing the one or more billets to the downstream cooling element. Incertain implementations, the method then includes opening the downstreamcooling element, advancing the one or more billets past the opendownstream cooling element, and closing the downstream cooling element.

In certain implementations, the method further includes, during theextruding, preventing a portion of the first billet that has not yetentered the rotating die from rotating. A centering insert may grip theportion of the first billet to prevent rotation of said portion, and thecentering insert may have an adjustable position relative to therotating die. The centering insert may be cooled with a cooling fluid.

In certain implementations, the method further includes quenching theextruded material when the extruded material exits the rotating die. Theextruded material may be quenched using water. In certainimplementations, the water contacts the extruded material withinapproximately 1 inch of the rotating die. In certain implementations,the rotating die comprises a plurality of stacked die plates. In certainimplementations, the material is copper, or the material is selectedfrom the group consisting of copper, aluminum, nickel, titanium, brass,steel, and plastic. The plurality of billets may extend alongsubstantially the entire length of the mandrel bar. In certainimplementations, the method includes flooding the interior of theextruded material with nitrogen. Each of the plurality of billets may beloaded onto the mandrel bar by a human or by an automated loadingdevice.

In one aspect, there is provided a method for continuously loading andextruding a plurality of billets, the method comprising receiving afirst billet at a receiving end of an elongate mandrel bar, transportingthe first billet along the mandrel bar and through cooling elements thatclamp to the mandrel bar and deliver cooling fluid to the mandrel bar,wherein at any given time at least one cooling element is clamped to themandrel bar, and extruding the first billet to form an extruded materialby pressing the first billet through a rotating die, wherein the firstbillet is followed by an adjacent second billet that forms a part of theextruded material.

In certain implementations, the first billet is transported along themandrel bar via a track that intermittently moves depending on theposition of the first billet relative to the cooling elements. Incertain implementations, the cooling fluid is transported to a mandrelbar tip provided on a second end of the mandrel bar opposite thereceiving end, and the cooling fluid is returned to the cooling elementsafter passing through the mandrel bar tip. The mandrel bar tip may bepositioned within the rotating die prior to receiving the first billet.In certain implementations, the cooling fluid is water.

In one aspect, an extrusion press system comprises a mandrel bar havinga first end and a second end, the first end for receiving a billethaving a hole therethrough and the second end coupled to a mandrel bartip, a cooling element coupled to the mandrel bar, the cooling elementhaving a port through which cooling fluid is delivered into the interiorof the mandrel bar for cooling the mandrel bar tip, a gripping elementcoupled to the mandrel bar, the gripping element comprising moveablegrips for securing in place and preventing rotation of the mandrel bar,and a rotating extrusion die configured to receive the billet from acentering insert having a plurality of notches that frictionally engagethe billet to prevent the billet from rotating prior to entry of thebillet into the rotating extrusion die, wherein the mandrel bar tip ispositioned within the rotating die.

In certain implementations, the extrusion press system further includesa press-ram element having moveable first and second arms that togethergrip the billet and provide a substantially constant pushing force inthe direction of the rotating die. The substantially constant pushingforce may cause the billet to enter the rotating die at a predeterminedrate. In certain implementations, the extrusion press system furthercomprises a motor coupled to a spindle that controls the rotation speedof the rotating extrusion die.

In certain implementations, the mandrel bar comprises an openingproximate to the cooling element ports, which opening receives thecooling fluid. The mandrel bar may further comprise notches about themandrel bar on either side of the opening, wherein the notches areconfigured to receive an o-ring to substantially prevent the coolingfluid from leaking. The mandrel bar may further comprise a mandrel barsleeve about the opening that substantially prevents the cooling fluidfrom leaking. In certain implementations, the mandrel bar comprises agrip portion that is correspondingly shaped to mate with the gripper ofthe gripping element. In certain implementations, the mandrel barcomprises an inner tube therein that receives the cooling fluid from thecooling element and through which the cooling fluid is delivered to themandrel bar tip. The cooling fluid may be returned to the coolingelement from the mandrel bar tip along a space within the mandrel barbetween the outer surface of the inner tube and the inner surface of themandrel bar. In certain implementations, the cooling fluid is water.

In certain implementations, the extrusion press system further comprisesa track along which the billet is transported, wherein the trackintermittently moves depending on the position of the billet relative tothe gripping elements and the cooling elements. The track may includeupper rolling wheels located above the track and configured to contactan upper surface of the billet. In certain implementations, theextrusion press system further comprises a quench tube provided at anexit of the rotating extrusion die. The quench tube quenches theextruded material when the extruded material exits the rotatingextrusion die. In certain implementations, the extruded material isquenched using water. The water may contact the extruded material withinapproximately 1 inch of the rotating extrusion die.

In one aspect, a system is provided for controlling at least in part theextrusion of a plurality of billets, and the system includes a processorconfigured to provide instructions to an extrusion press system forloading a first billet at a receiving end of an elongate mandrel bar,transporting the first billet along the mandrel bar and through grippingelements that secure in place and prevent rotation of the mandrel bar,wherein at any given time at least one gripping element is gripping themandrel bar, and extruding the first billet to form an extruded materialby pressing the first billet through a rotating die, wherein the firstbillet is followed by an adjacent second billet that forms a part of theextruded material.

In certain implementations, the processor is further configured toprovide instructions to an extrusion press system for intermittentlymoving a track upon which the first billet is placed based on thelocation of the first billet with respect to the gripping elements. Incertain implementations, the processor is further configured to provideinstructions to an extrusion press system for adjusting a rotation speedof the rotating die. In certain implementations, the processor isfurther configured to provide instructions to an extrusion press systemfor monitoring a cooling fluid delivery system. In certainimplementations, the processor is further configured to provideinstructions to an extrusion press system for adjusting the advancingand retraction speeds of press-rams that deliver the plurality ofbillets to the rotating die.

In one aspect, a non-transitory computer-readable medium is provided forcontrolling at least in part the extrusion of a plurality of billets,the non-transitory computer-readable medium comprising logic recordedthereon for loading a first billet at a receiving end of an elongatemandrel bar, transporting the first billet along the mandrel bar andthrough gripping elements that secure in place and prevent rotation ofthe mandrel bar, wherein at any given time at least one gripping elementis gripping the mandrel bar, and extruding the first billet to form anextruded material by pressing the first billet through a rotating die,wherein the first billet is followed by an adjacent second billet thatforms a part of the extruded material.

In certain implementations, the non-transitory computer-readable mediumfurther comprises logic recorded thereon for intermittently moving atrack upon which the first billet is placed based on the location of thefirst billet with respect to the gripping elements. In certainimplementations, the non-transitory computer-readable medium furthercomprises logic recorded thereon for adjusting a rotation speed of therotating die. In certain implementations, the non-transitorycomputer-readable medium further comprises logic recorded thereon formonitoring a cooling fluid delivery system. In certain implementations,the non-transitory computer-readable medium further comprises logicrecorded thereon for adjusting the advancing and retraction speeds ofpress-rams that deliver the plurality of billets to the rotating die.

In one aspect, an extrusion press system comprises a mandrel bar havinga first end and a second end, the first end for receiving a billethaving a hole therethrough and the second end coupled to a mandrel bartip, cooling means for delivering cooling fluid into the interior of themandrel bar for cooling the mandrel bar tip, gripping means for securingin place and preventing rotation of the mandrel bar, and rotatingextrusion means for extruding the billet, wherein the rotating extrusionmeans receives the billet from centering means having a plurality ofnotches that frictionally engage the billet to prevent the billet fromrotating prior to entry of the billet into the rotating extrusion means,wherein the mandrel bar tip is positioned within the rotating extrusionmeans.

In certain implementations, the extrusion press system further includespressing means for gripping the billet and providing a substantiallyconstant pushing force in the direction of the rotating extrusion means.The substantially constant pushing force may cause the billet to enterthe rotating extrusion means at a predetermined rate. In certainimplementations, the extrusion press system further includes means forcontrolling the rotation speed of the rotating extrusion means.

In certain implementations, the mandrel bar comprises an openingproximate to the cooling means, which opening receives the coolingfluid. The mandrel bar may further comprise notches about the mandrelbar on either side of the opening, wherein the notches are configured toreceive an o-ring to substantially prevent the cooling fluid fromleaking. The mandrel bar may further comprise a mandrel bar sleeve aboutthe opening that substantially prevents the cooling fluid from leaking.In certain implementations, the mandrel bar may further comprise a gripportion that is correspondingly shaped to mate with the gripping means.In certain implementations, the mandrel bar comprises an inner tubetherein that receives the cooling fluid from the cooling means andthrough which the cooling fluid is delivered to the mandrel bar tip. Thecooling fluid may be returned to the cooling means from the mandrel bartip along a space within the mandrel bar between the outer surface ofthe inner tube and the inner surface of the mandrel bar. In certainimplementations, the cooling fluid is water.

In certain implementations, the extrusion press system further comprisesa track along which the billet is transported, wherein the trackintermittently moves depending on the position of the billet relative tothe gripping means and the cooling means. The track may include upperrolling wheels located above the track and configured to contact anupper surface of the billet. In certain implementations, the extrusionpress system further comprises quenching means provided at an exit ofthe rotating extrusion means. The quenching means quenches the extrudedmaterial when the extruded material exits the rotating extrusion means.In certain implementations, the extruded material is quenched usingwater. The water may contact the extruded material within approximately1 inch of the rotating extrusion means.

In one aspect, a method for continuously extruding a plurality ofbillets comprises transporting, along a non-rotating mandrel bar, theplurality of billets from a first end of the mandrel bar to a second endof the mandrel bar, and extruding the plurality of billets by pressingeach of the plurality of billets through a rotating die, whereinfriction from the rotation of the rotating die against the non-rotatingplurality of billets generates heat for deforming the plurality ofhollow billets, wherein a mandrel bar tip is positioned within therotating die at the second end of the mandrel bar. In certainimplementations, the method includes, during the extruding, preventing aportion of a respective one of the plurality of billets that has not yetentered the rotating die from rotating. In certain implementations, acentering insert grips the portion of the respective billet to preventrotation of said portion, and the centering insert has an adjustableposition relative to the rotating die. In certain implementations, themethod further includes cooling the mandrel bar tip during theextruding.

In one aspect, a die for extruding a material includes a die body havinga passage defining an entrance and an exit, with the diameter of theexit being smaller than the diameter of the entrance, and an interiorsurface extending around the passage from the entrance to the exit. Abase is coupled to the die body, and rotation of the base causes the diebody to rotate.

In certain implementations, the die body is configured to receive abillet of material for extrusion, and the billet is not pre-heatedbefore entering the die body. Rotation of the die body creates frictionbetween the interior surface and a billet advanced through the entranceand into the interior passage of the die body. The friction heats thebillet to a temperature that is sufficient to cause deformation of thebillet material. In certain implementations, the die body is configuredto receive a mandrel tip through the entrance such that the mandrel tipis positionable within the interior passage of the die body. Theinterior surface of the die may include an angled portion configured tobe positioned near a corresponding tapered outer surface of the mandreltip. The die body is configured to receive a billet pressed through theinterior passage of the die body to form an extruded product, theextruded product having an outer diameter corresponding to the diameterof the exit of the die body and an inner diameter corresponding to adiameter of the mandrel tip.

In certain implementations, the die body includes a plurality of dieplates coupled together to form a stack. Each die plate has a circularbore through the center of the plate, and perimeters of the bores formthe interior surface in the die body. The perimeter of the bores areangled at different angles with respect to an axis extending through thedie body from the entrance to the exit. An angle of the perimeter near afront face of each plate in the die body is greater than an angle of theperimeter near a back face of an adjacent plate. The stack may include anon-uniform die plate having a bore perimeter angled at first angle neara front face of the plate and angled at a different second angle near arear face of the plate. At least one of the die plates is formed fromtwo different materials, with a first material forming a perimeter of abore in the die plate and a second material forming an outer portion ofthe die plate. The first material may be a ceramic material, a steel, ora consumable material. In certain implementations, a front face of thedie body near the entrance is configured to mate with a centering inserthaving a diameter substantially equal to the diameter of the entrance.The centering insert and a perimeter of the entrance may be formed fromthe same material. The centering insert does not rotate when the baseand die rotate. In certain implementations, the base comprises acircular bore having a diameter greater than the diameter of the exit ofthe die body. A motor may supply a rotational force to the base.

In one aspect, a die includes a means for extruding a material, and themeans for extruding includes a passage means defining an entrance and anexit, where the diameter of the exit is smaller than the diameter of theentrance, and an interior surface means extending around the passagemeans from the entrance to the exit. The die also has a means forcoupling the means for extruding to a rotation means, and rotation ofthe means for coupling causes the means for extruding to rotate.

In certain implementations, the means for extruding is configured toreceive a billet of material for extrusion, and the billet is notpre-heated before entering the die body. Rotation of the means forextruding creates friction between the interior surface means and abillet advanced through the entrance and into the passage means of themeans for extruding. The friction heats the billet to a temperature thatis sufficient to cause deformation of the billet material. The means forextruding is configured to receive a rod tip means through the entrancesuch that the rod tip means is positionable within the passage means ofthe means for extruding. The interior surface means of the means forextruding includes an angled portion configured to be positioned near acorresponding tapered outer surface of the rod tip means. The means forextruding is configured to receive a billet passed through the passagemeans of the means for extruding to form an extruded product, theextruded product having an outer diameter corresponding to the diameterof the exit of the means for extruding and an inner diametercorresponding to a diameter of the rod tip means.

In certain implementations, the means for extruding comprises aplurality of plate means coupled together to form a stack. Each platemeans has a circular bore through the center of the plate means, andperimeter of the bores form the interior surface means in the means forextruding. The perimeters of the bores are angled at different angleswith respect to an axis extending through the means for extruding fromthe entrance to the exit. An angle of the perimeter near a front face ofeach plate means in the means for extruding is greater than an angle ofthe perimeter near a back face of an adjacent plate means. The stack mayinclude a non-uniform plate means having a bore perimeter angled at afirst angle near a front face of the plate means and angled at adifferent second angle near a rear face of the plate means. At least oneof the plate means is formed from two different materials, with a firstmaterial forming a perimeter of a bore in the plate means and a secondmaterial forming an outer portion of the plate means. The first materialmay be a ceramic material, a steel, or a consumable material. A frontface of the means for extruding near the entrance is configured to matewith a centering means having a diameter substantially equal to thediameter of the entrance. The centering means and a perimeter of theentrance may be formed from the same material. Wherein the centeringmeans does not rotate when the means for coupling and the means forextrusion rotate. The centering means includes gripping means thatprevent rotation of a billet passing through the centering means. Incertain implementations, the means for coupling comprises a circularbore having a diameter greater than the diameter of the exit of themeans for extruding, and a power means may supply a rotational force tothe means for coupling.

Variations and modifications of these embodiments will occur to those ofskill in the art after reviewing this disclosure. The foregoing featuresand aspects may be implemented, in any combination and subcombination(including multiple dependent combinations and subcombinations), withone or more other features described herein. The various featuresdescribed or illustrated herein, including any components thereof, maybe combined or integrated in other systems. Moreover, certain featuresmay be omitted or not implemented.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and advantages will be apparent uponconsideration of the following detailed description, taken inconjunction with the accompanying drawings, in which like referencecharacters refer to like parts throughout, and in which:

FIG. 1 shows a side elevation view of an illustrative extrusion presssystem;

FIG. 2 shows a side elevation view of an illustrative billet feed trackassembly for use with the extrusion press system of FIG. 1;

FIG. 3 shows a perspective view of an illustrative fluid clamp;

FIGS. 4 and 5 show front and side elevation views, respectively, of thefluid clamp of FIG. 3;

FIG. 6 shows a schematic view of an illustrative mandrel bar having anopening or port for receiving cooling fluid;

FIG. 7 shows a perspective view and various cross-sectional and sideviews of an illustrative mandrel bar sleeve;

FIG. 8 shows a perspective cross-sectional view of an illustrativemandrel bar having an inner tube for delivering cooling fluid to amandrel bar tip;

FIG. 9 show a schematic diagram of an illustrative fluid deliverysystem;

FIG. 10 shows a perspective view of an illustrative mandrel bar grip;

FIGS. 11 and 12 show front elevation views of the mandrel bar grip ofFIG. 10 in a gripping position (11) and a non-gripping position (12);

FIG. 13 shows a schematic view of an illustrative mandrel bar having aportion that mates with a mandrel bar grip;

FIG. 14 shows a perspective view of the mandrel bar portion of FIG. 13;

FIG. 15 shows a perspective view of an illustrative press-ram assemblyhaving guide members;

FIG. 16 show a perspective view of an illustrative press-ram platen;

FIGS. 17-19 show front, side, and rear elevation views, respectively, ofthe press-ram platen of FIG. 16;

FIG. 20 shows a perspective view of an illustrative press-ram platen;

FIGS. 21-23 show front, side, and rear elevation views, respectively, ofthe press-ram platen of FIG. 20;

FIG. 24 shows an illustrative rotating die and centering ring in anextrusion orientation;

FIG. 25 shows an illustrative cross-sectional view of the rotating dieand centering ring of FIG. 24;

FIG. 26 shows an illustrative cross-sectional view of the rotating dieand centering ring of FIG. 24;

FIG. 27 shows a cross-sectional view the rotating die of FIG. 24 with amandrel bar positioned therein;

FIG. 28 shows a cross-sectional view of a billet being extruded throughthe rotating die of FIG. 27;

FIGS. 29 and 30 show a perspective view and a top plan view,respectively, of illustrative mandrel bar tips;

FIG. 31 shows an illustrative flowchart for pre-processing a billet foruse in the extrusion press system of FIG. 1;

FIG. 32 shows an illustrative flowchart for pre-processing a mandrel bartip for use in the extrusion press system of FIG. 1;

FIGS. 33-36 show illustrative flowcharts for operating the extrusionpress system of FIG. 1;

FIG. 37 shows a block diagram of an illustrative computer system foroperating the extrusion press system of FIG. 1;

FIG. 38 shows a cross-sectional view of a magnetic data storage mediumencoded with a set of machine-executable instructions for performing themethods of the present disclosure;

FIG. 39 shows a cross-sectional view of an optically readable datastorage medium encoded with a set of machine-executable instructions forperforming the methods of the present disclosure;

FIG. 40 shows a simplified block diagram of an illustrative systememploying a programmable logic controller of the present disclosure; and

FIG. 41 shows a block diagram of an illustrative system employing aprogrammable logic controller of the present disclosure.

DETAILED DESCRIPTION

To provide an overall understanding of the systems, devices, and methodsdescribed herein, certain illustrative embodiments will be described.Although the embodiments and features described herein are specificallydescribed for use in connection with continuous extrusion press systems,it will be understood that all the components, connection mechanisms,manufacturing methods, and other features outlined below may be combinedwith one another in any suitable manner and may be adapted and appliedto systems to be used in other manufacturing processes, including, butnot limited to cast-and-roll, up-cast, heat treatment, other extrusion,and other manufacturing processes. Furthermore, although the embodimentsdescribed herein relate to extruding metal tubing from hollow billets,it will be understood that the systems, devices, and methods herein maybe adapted and applied to systems for extruding any suitable type ofextruded product using billets.

The extrusion press system operates using frictional heat generated froma non-rotating hollow billet coming into contact with a rotating die tofacilitate deformation and extrusion of the billet. There is thus norequirement of pre-heating the billets or the rotating die before theextrusion. The amount of heat generated is generally determined by therate at which the billets are fed into the rotating die (e.g.,controlled by the press-ram speed of the press-ram elements 130, 140 ofFIG. 1) and the rotation speed of the die (e.g., controlled by therotation speed of the spindle 172 of FIG. 1), as well as the interiorprofile of the rotating die. Higher press-ram speeds and spindlerotation speeds generate relatively greater amounts of heat.

The rotating die forms the outer diameter of an extruded tube producedby the extrusion press system, and a mandrel bar tip positioned withinthe rotating die forms the inner diameter of the extruded tube. Incertain embodiments, chilled process water, or any other suitablecooling fluid, is used to cool the process elements including therotating die, the centering insert, the billets, and the gear box oil,as well as the extruded tubing product. Unlike conventional extrusiontechniques, the extrusion press system of the present disclosure doesnot require any container within which to hold the billet for extrusion.Therefore the billets to be extruded preferably have sufficient columnstrength to withstand the pressure applied by the press-ram elementsduring the extrusion process. A programmable logic controller, or PLC,controls all or a subset of movements of the extrusion press systemwhile the system is set in automatic mode.

The extrusion press systems, devices, and methods described herein mayprovide for continuous extrusion of a plurality of billets to produce aseamless extruded tubing product according to various seamless tubingstandards including, for example, the ASTM-B88 Standard Specificationfor Seamless Copper Water Tube. The seamless extruded tubing of thepresent disclosure may also comply with the standards under NSF/ANSI-61for Drinking Water System Components.

FIG. 1 shows an extrusion press system 10 according to certainembodiments. The extrusion press system 10 includes structural sectionsreferred to herein as the mandrel carriage section 80 and the platenstructure section 90. The mandrel carriage section 80 includes a mandrelbar 100, fluid clamps or cooling elements 102 and 104, mandrel grips orgripping elements 106 and 108, and a billet delivery system 110 shown indetail in FIG. 2. The mandrel carriage section 80 is supported by aphysical carriage structure, which is not shown in FIG. 1 to avoidovercomplicating the drawing, but which carriage structure serves as amount for the components of the mandrel carriage 80. The platenstructure section 90 includes an entry platen 120 and a rear die platen122, press-ram platens 130 and 140, a centering platen 150, and arotating die 160 that presses against the rear die platen 122. Theplaten structure section 90 is supported by a frame 190 that also servesas a mount for the motor 170 and related gearbox components (not shown).The direction along which billet loading, transport, and extrusionoccurs according to the extrusion press system 10 is denoted bydirectional process arrow d₁. The extrusion press system 10 may beoperated, at least in part, by a PLC system that controls variousaspects of the billet delivery subsystem 20, extrusion subsystem 40, andquenching or cooling subsystem 60 of the extrusion press system 10.

The mandrel grips 106, 108 comprise a mandrel bar gripping system 105designed to hold the mandrel bar in place while allowing a plurality ofbillets to be continuously fed along and about the mandrel bar 100 toprovide for continuous extrusion. The billets may be formed from anysuitable material for use in extrusion press systems including, but notlimited to, various metals including copper and copper alloys, or anyother suitable non-ferrous metals such as aluminum, nickel, titanium,and alloys thereof, ferrous metals including steel and other ironalloys, polymers such as plastics, or any other suitable material orcombinations thereof. The mandrel grips 106, 108 may be controlled bythe PLC system to securely hold the mandrel bar 100 such that at anygiven time during the extrusion process, at least one of the mandrelgrips 106, 108 is gripping the mandrel bar 100. The mandrel grips 106,108 set the position of the mandrel bar 100 and prevent the mandrel bar100 from rotating. When the mandrel grips 106, 108 are in a gripping orengaged position, thereby gripping the mandrel bar 100, the mandrelgrips 106, 108 prevent billets from being transported along the mandrelbar 100 through the grips.

The mandrel grips 106, 108 operate by alternately gripping or engagingthe mandrel bar 100 to allow one or more billets to pass through arespective mandrel grip at a given time. For example, the upstreammandrel grip 106 may release or disengage the mandrel bar 100 while thedownstream mandrel grip 108 is gripping the mandrel bar 100. At anygiven time, at least one of the mandrel grips 106, 108 is preferablygripping or otherwise engaged with the mandrel bar 100. One or morebillets queued or indexed near the upstream mandrel grip 106, or beingtransported along the mandrel bar 100, may pass through the openupstream mandrel grip 106. After a specified number of billets haspassed through the open upstream mandrel grip 106, the gripper 106 mayclose and thereby return to gripping the mandrel bar 100, and thebillets may be advanced to the downstream gripping element 108. Thedownstream gripping element 108 may remain closed, thereby gripping themandrel bar 100, or the downstream mandrel grip 108 may open after theupstream mandrel grip 106 re-grips the mandrel bar 100. Although twomandrel grips 106, 108 are shown in the extrusion press system 10, itwill be understood that any suitable number of mandrel grips may beprovided.

The fluid clamps 102, 104 comprise a mandrel bar fluid delivery system101 designed to supply cooling fluid along the interior of the mandrelbar 100 to the mandrel bar tip during the extrusion process. The fluidclamps 102, 104 also receive cooling fluid from the mandrel bar 100 thathas returned from the mandrel bar tip. Any suitable cooling fluid may beused, including water, various mineral oils, brines, synthetic oils, anyother suitable cooling fluid, including gaseous fluids, or anycombination thereof. The fluid clamps 102, 104 may be controlled by thePLC system to continuously supply process cooling fluid to the mandrelbar during the extrusion process while allowing a plurality of billetsto be continuously feed along and about the mandrel bar 100. The fluidclamps 102, 104 operate such that there is no or substantially nointerruption to the supply of process cooling fluid to the mandrel bartip during the extrusion process. Similar to the operation of themandrel grips 106, 108 discussed above, when the fluid clamps 102, 104are clamped to or engaged with the mandrel bar 100, the fluid clamps102, 104 prevent billets from being transported along the mandrel bar100 through the fluid clamps.

The fluid clamps 102, 104 operate such that at any given time during theextrusion at least one of the fluid clamps is clamped to or engaged withthe mandrel bar 100 and thereby delivers cooling fluid into the mandrelbar 100 for delivery to the mandrel bar tip. When a billet passesthrough one of the fluid clamps 102, 104, the respective fluid clampdiscontinues delivering (and receiving) cooling fluid and releases ordisengages the mandrel bar 100 to allow the billet to pass therethroughbefore re-clamping the mandrel bar 100 and continuing to deliver (andreceive) cooling fluid. While one of the fluid clamps 102, 104 isunclamped or disengaged from the mandrel bar 100, the other fluid clampcontinues to deliver cooling fluid to the mandrel bar.

For example, the upstream fluid clamp 102 may release the mandrel bar100 while the downstream fluid clamp 104 is clamped to the mandrel bar100. At any given time, at least one of the fluid clamps 102, 104 ispreferably clamped to the mandrel bar 100 to continuously delivercooling fluid. One or more billets queued or indexed near the upstreamfluid clamp 102, or being transported along the mandrel bar 100, maypass through the open upstream fluid clamp 102. After a specified numberof billets has passed through the open upstream fluid clamp 102, thefluid clamp 102 may close and thereby return to clamping the mandrel bar100 and delivering cooling fluid, and the billets may be advanced to thedownstream fluid clamp 104. The downstream fluid clamp 104 may remainclosed, thereby clamping the mandrel bar 100, or the downstream fluidclamp 104 may open after the upstream fluid clamp 102 re-clamps to themandrel bar 100. Although two fluid clamps 102, 104 are shown in theextrusion press system 10, it will be understood that any suitablenumber of fluid clamps may be provided.

The billet delivery system 20 includes the billet feed track assembly110 of FIG. 2. The billet delivery system 110 ensures that a continuoussupply of billets, such as billet 30, is present for the extrusionprocess. When additional billets are needed, the PLC system will cyclethe proper mandrel bar grips 106, 108, fluid clamps 102, 104, and billetdelivery rollers (e.g., the billet feed track assembly 110) to ensurethat the billet supply is continuous. The section of the mandrelcarriage 80 located between the mandrel grip 106 and the entry platen120 may continuously index to minimize the gap between billets fed intothe ram platen sections 141 of the platen structure 90. For example, atthis location of the mandrel carriage 80, the track assembly 110 maycontinuously cycle the track 202 to feed billets into the platenstructure 90.

The billet feed track assembly 110 includes a chain or a track 202positioned about sprockets 204 and 205. One or more of the sprockets204, 205 may be coupled to a motor (not shown) that operates to move orcycle the track 202 in a loading direction, d₂. The track 202 andsprockets 204, 205 are supported by a base rail 206 and a low rail 208,which together couple to a frame 210. An upper portion 210 a of theframe 210 includes top roller wheels 212 that provide an upper bound fora passing billet 30. For example, as show in FIG. 2, the mandrel bar 100includes a billet 30 loaded thereon, where the billet 30 moves viacontact with the track 202 and is stabilized by the top roller wheels212. The billet feed track assembly 110 may have any suitable length.For example, the track assembly 110 may extend along substantially thelength of the mandrel bar 100 within the mandrel carriage section 80. Incertain embodiments, there may be provided a plurality of trackassemblies that together operate to feed billets along the mandrel bar100 and into the platen structure section 90. For example, there may betrack assemblies provided along the mandrel bar 100 between each of thefluid clamps 102, 104 and the mandrel grips 106, 108 such that one ormore billets can be independently cycled through respective fluid clamps102, 104 and mandrel grips 106, 108, without requiring transport ofother billets as would occur if there were only a single track assembly.

Returning to FIG. 1, the mandrel bar 100 extends along substantially thelength of the extrusion press system 10 and is positioned to place themandrel bar tip within the rotating die 160. The adjustment to properlyposition the mandrel bar tip within the rotating die 160 is accomplishedby moving the mandrel carriage section 80, thus moving the mandrel bar100. The adjustments to the mandrel bar 100 and the mandrel carriagesection 80 may be towards or away from the die 160. The mandrel bar 100and the mandrel carriage section 80 preferably cannot be adjusted whilethe extrusion press system 10 is in operation, although it will beunderstood that in certain embodiments the mandrel bar 100 and/ormandrel carriage section 80 may be adjusted during operation.

As discussed above, the extrusion press system 10 includes a platenstructure section 90 having an entry platen 120 and a rear die platen122, press-ram platens 130 and 140, a centering platen 150, and arotating die 160 pressed against the rear die platen 122. Near the entryplaten 120 is the press-ram assembly 141 that includes a first press-ramplaten 130 and a second press-ram platen 140. The first and secondpress-ram platens 130, 140 feed billets into the centering platen 150,which grips the billets and prevents the billets from rotating prior toentering the rotating die 160, which presses against the rear die platen122. The entry platen 120 and the rear die platen 122 are coupled by aseries of tie rods 124 that act as guides for the press-ram platens 130,140 and the centering platen 150, each of which includes bearings 126 a,126 b, 126 c that move along the tie rods 124. The rear die platen 122and the entry platen 120 have mounting locations 127 through which thetie rods 124 are fixed. The entry platen 120, rear die platen 122, andtie rod structure 124 are supported by the frame 190. The frame 190 alsoholds the spindle 172 and motor 170. At the exit of the rotating die 160is a quench tube 180 for rapidly cooling the extruded tubing.

The press-ram platens 130, 140 operate by gripping the billets andproviding a substantially constant pushing force in the direction of theextrusion die stack 160. At any given time at least one of the press-ramplatens 130, 140 grips a billet and advances the billet along themandrel bar 100 to provide the constant pushing force. The press-ramplatens 130, 140 form the final part of the billet delivery subsystem 20before the billet enters the centering platen 150 and the rotating die160 of the extrusion subsystem 40. Similar to the billet feed tracksection before the entry platen 120, the section prior to the press-ramplatens 130, 140 preferably continuously indexes the billets to minimizeany gaps between a billet that is gripped the press-ram platens 130, 140and the next billet.

As discussed above, the press-rams 130, 140 continuously push billetsinto the rotating die 160. The press-rams 130, 140 alternate grippingand advancing billets towards and into the rotating die 160 and thenungripping the advanced billets and retracting for the nextgripping/advancing cycle. There is preferably an overlap between thetime when one press-ram stops pushing and the other press-ram is aboutto start pushing so that there is always pressure on the rotating die160. The press-rams 130, 140 advance and retract via press-ram cylinderscoupled to the respective press-ram. As shown there are two press-ramcylinders 132, 142 per press-ram. A first set of press-ram cylinders 132is located to the left and right of the entry platen 120 (although theright-side press-ram cylinder is hidden from view by the left-sidepress-ram cylinder). The first set of press-ram cylinders 132 coupleswith the first press-ram platen 130 and is configured to move the firstpress-ram 130 along the tie rods 124 as the first press-ram 130 advancesbillets and then retracts for subsequent billets. A second set ofpress-ram cylinders 142 is located on the top and bottom of the entryplaten 120. The second set of press-ram cylinders 142 couples with thesecond press-ram platen 140 and is configured to move the secondpress-ram 140 along the tie rods 124 as the second press-ram 140advances billets and then retracts for subsequent billets. Although twopress-ram cylinders are shown for each of the first and second press-ramplatens 130, 140, it will be understood that any suitable number ofpress-ram cylinders may be provided. In certain embodiments, press-ramcylinders may be coupled to both press-rams 130, 140.

The centering platen 150 receives billets advanced by the press-rams130, 140 and holds the billets to prevent their rotation during theextrusion process prior to entry of the billets into the rotating die160. When the centering platen 150 is positioned in place for theextrusion process, the centering platen 150 becomes part of theextrusion die 160. That is, a centering insert 152 of the centeringplaten 150 substantially abuts the rotating die 160. The centeringplaten 150 itself, however, and the components therein including thecentering insert 152, do not rotate with the rotating die 160. Thecentering platen 150 prevents billets that are no longer held by thesecond press-ram 150 from rotating while the die 160 rotates by grippingthe billets and thereby preventing the billets from rotating prior toentry of the billets into the rotating die 160.

The rotating die 160 may have a unibody design, or may include aplurality of die plates stacked together. In certain embodiments, thedie includes a base plate, a final plate, a second intermediate plate, afirst intermediate plate, an entry plate, and a steel end holder, andthe die plates are bolted together to form the die 160. The rotating die160 is bolted to or otherwise coupled with the spindle 172, which isoperated by the motor 170. A gear box is bolted to the rear die platen122 and contains the spindle 172 as well as the drive chain, motor drivegear, gear oil reservoir, and gear oil heat exchanger, which are notshown in FIG. 1 to avoid overcomplicating the figure. In certainembodiments, the spindle motor 170 and the spindle/die gear tooth ratiois 2.5:1, although it will be understood that any suitable gear ratiomay be used for the rotation of the rotating die 160.

At the extrusion end of the extrusion press system 10 is a quench box185 bolted or otherwise coupled to the exit side of the gear box on therear die platen 122. In certain embodiments, within the quench box 185is a quench tube 180 for rapidly quenching or cooling the extrudedmaterial as it exits the rotating die 160. Water may be used as thequenching or cooling fluid, and the water may contact the extrudedmaterial sometime after the exit of the extruded material from therotating die 160. For example, in certain embodiments, the extrudedmaterial is quenched with cooling fluid within approximately 1 inch ofexiting the rotating die 160. Any suitable cooling fluid may be used forquenching an extruded material, including water, various mineral oils,brines, synthetic oils, any other suitable cooling fluid, includinggaseous fluids, or any combination thereof. The quench tube 180 may beformed of one or more tubes having a channel therein for delivering thecooling fluid to the extruded material. In certain embodiments, thequench tube 180 further includes an end cap or other structure throughwhich the cooling fluid is delivered to the extruded material. Anysuitable quench tube may be used the extrusion press system of thisdisclosure, including, for example, the quench tubes described incopending, commonly-assigned U.S. patent application Ser. No. [______](Attorney Docket No. 109965-0006-101), filed concurrently herewith, andentitled “SYSTEMS AND METHODS FOR COOLING EXTRUDED MATERIALS,” thedisclosure of which is hereby incorporated by reference herein in itsentirety.

In certain embodiments, nitrogen gas, or another suitable inert gas, isdelivered to the interior of an extruded material as the material exitsthe rotating die. For example, nitrogen gas may be delivered to theinterior of extruded tubing using a cap placed on the leading end of theextruded tubing as it exits the rotating die. Injecting gaseous orliquid nitrogen into the rotating die assembly, or the interior of theextruded material itself, can minimize oxide formation by displacing theoxygen-laden air.

Although not shown in FIG. 1, the billet delivery subsystem 20 of theextrusion press system 10 may include a billet delivery table with aplurality of billets prepped for loading onto the extrusion press system10. The billets may be loaded automatically, for example, by anautomated process or may be loaded by hand.

The various components of the extrusion press system 10 of FIG. 1 willnow be described with respect to FIGS. 3-30. FIG. 3 shows a perspectiveview of the fluid clamp 102 of FIG. 1 according to certain embodiments.The fluid clamp 102 includes a housing 302 having a base 304 and endplates 306 a and 306 b coupled via four tie rods 308, although it willbe understood that any suitable number of tie rods may be used, and incertain embodiments other fixation techniques may be used to secure theelements of the fluid clamp in addition to, or in place of, the tie rods308. Supported by the tie rods 308 is an inlet/outlet fluid clamp 312,through which cooling fluid such as water enters and exits the fluidclamp 102, and a blank fluid clamp 314, each of which is actuated by arespective cylinder 309, 310 located between the respective clamp 312,314 and its end plate 306 a, 306 b. Situated below the housing 302 arecarriage rails 305 that secure the fluid clamp 102 onto the carriagestructure that supports the mandrel carriage section 80 of FIG. 1. Theinlet/outlet fluid clamp 312 includes taps 316 formed in a top surface312 a therein that extend to an insert piece 318 that is inserted intoan inner portion of the inlet/outlet fluid clamp 312. As can be seen inFIG. 3, the blank fluid clamp 314 has a clamping surface 314 a and theinsert 318 within the inlet/outlet fluid clamp 312 has a clampingsurface 318 a. The clamping surfaces 314 a and 318 a frictionally engagea respective surface of the mandrel bar, such as the mandrel bar 100 ofthe extrusion press system 10. In certain embodiments, the clampingsurfaces 314 a, 318 a may engage a mandrel bar sleeve (e.g., mandrel barsleeve 360 of FIG. 7) provided about a portion of the mandrel bar.

FIGS. 4 and 5 show front and side elevation views, respectively, of thefluid clamp 102 of FIG. 3. As shown in FIGS. 4 and 5, for example, thetaps 316 in the inlet/outlet fluid clamp 312 extend from the top surface312 a of the clamp 312 and into ports 320 formed in the insert 318. Thefluid clamp 102 delivers cooling fluid to the mandrel bar via theinlet/outlet fluid clamp 312 through the taps 316 and the ports 320.Also shown in FIG. 4 are the clamping surfaces 314 a and 318 a of theinlet/outlet fluid clamp 312 and the blank fluid clamp 314. Although thefluid clamp 312 includes two taps 316 in fluid communication with twoports 320 of the insert 318, it will be understood that any suitablenumber of taps and ports may be provided for delivering cooling fluid tothe mandrel bar. Alternatively, or additionally, in certain embodimentsthe taps 316 may be provided through other surfaces of the fluid clampsuch as the front (or rear) surface 312 b or the lateral surfaces 312 cof the inlet/outlet fluid clamp 312.

In certain embodiments, the clamping surfaces 314 a and 318 a of theblank fluid clamp 314 and the insert 318 of the inlet/outlet fluid clamp312 are structured to mate with a corresponding portion of a mandrelbar. FIG. 6 shows a schematic view of a mandrel bar 340 having anopening or port 344 for receiving and/or returning cooling fluid from afluid clamp according to certain embodiments. As shown in FIG. 6, forexample, the mandrel bar 340 includes portions 342 and 348 having tworespective port sections 342 a, 342 b and 348 a, 348 b for receivingand/or returning cooling fluid from a fluid clamp such as fluid clamp102. In certain embodiments, port sections 342 a and 348 a areconfigured for the return of cooling fluid to a fluid clamp, and theport sections 342 b and 348 b are configured for the receipt of coolingfluid from the fluid clamp. Alternatively, port sections 342 a and 348 amay receive cooling fluid, and port sections 342 b and 348 b may returnthe cooling fluid. In still further embodiments, port sections 342 a/348b may receive cooling fluid and port sections 342 b/348 a may returncooling fluid, or vice versa. Any suitable receiving/returningarrangement of port sections may be used such that at least one of therespective ports receives cooling fluid and another returns the coolingfluid to the fluid clamp.

The inset of the mandrel bar portion 342 shows port section 342 a withan opening or port 344 for receiving and/or returning cooling fluid fromthe fluid clamp 102. The mandrel port 344 is sized to correspond withthe respective port 320 of the fluid clamp 102. About the mandrel port344 are a series of notches 346 receiving o-rings and thereby preventingcooling fluid from escaping or otherwise leaking from the mandrel bar340 via the port 344. The two mandrel bar portions 342, 348 correspond,for example, to the portions of the mandrel bar that interface with thetwo fluid clamps 102, 104 of the extrusion press system 10 of FIG. 1. Asdiscussed above, in certain embodiments a mandrel sleeve 360 may beprovided to engage the clamping surfaces of a fluid clamp. The mandrelsleeve 360 may also work together with the o-rings to prevent fluidleakage from the mandrel bar 340 and the fluid clamp. As shown in FIG.7, for example, a mandrel sleeve 360 includes ports 360 through whichcooling fluid is delivered and/or returned between the mandrel bar 340and a fluid clamp. The mandrel sleeve 360 also includes a slot 364 thatallows for flexibility as the sleeve 360 is positioned on the mandrelbar 340 about the portions 342, 348 that receive and/or return coolingfluid. The o-rings in notches 346 may create a substantially fluid-tightseal between the mandrel bar 340 and the inner surface 360 a of themandrel bar sleeve 360.

Also shown in FIG. 6 is an inner tube 350 that runs along the length ofthe mandrel bar 340 and which delivers the cooling fluid to the mandrelbar tip, which is positioned within a rotating die. The cooling fluidthat is received through the openings or ports 344 in the mandrel bar340 travels through an opening 354 in the inner tube 350 such that thecooling fluid is delivered along the inside of the tube 350 to themandrel bar tip, where it then travels back out of the tube 350, butwithin the mandrel bar, to the openings or ports 344 from which it wasreceived. The direction of cooling fluid travel is shown in in FIG. 8,which depicts a perspective cross-sectional view of the mandrel bar 340and the inner tube 350 of FIG. 6 for delivering cooling fluid to themandrel bar tip. The cooling fluid travels along the inside of the innertube 350 in the direction of arrow W1 towards the mandrel bar tip andthen returns in the direction of arrow W2 in the outer space 352 betweenthe outer surface 350 a of the inner tube 350 and the inner surface 340a of the mandrel bar 340. In certain embodiments, a portion of the innersurface of the mandrel bar, such as the inner surface 340 a of mandrelbar 340, may be threaded for receiving the mandrel bar tip, although themandrel bar tip may be coupled to the mandrel bar using any suitabletechnique. In certain embodiments, a spacer may be provided about theinner tube 350 that centers the inner tube 350 within the mandrel bar340 along any suitable length of the mandrel bar 340. Where the mandrelbar has threads, the spacer may be threaded to the mandrel bar, althoughthe spacer may also press against non-threaded portions of the mandrelbar.

The extrusion press system 10 includes a cooling system 400 for coolingthe various components of the press system 10 during operation. Althoughthe cooling system 400 of FIG. 9 will be described as using water as thecooling fluid, it will be understood that any suitable cooling fluid maybe used. The extrusion press cooling system 400 is designed to delivercooled water in sufficient quantities and pressures to cool the processcomponents and the extruded product. In certain embodiments, there maybe two main water systems on the press, mandrel water and press water.With respect to the mandrel water, the mandrel water system is suppliedwater from the holding tank. The heat exchangers cool the process waterby exchanging the heat generated during the extrusion process withchilled water from the chiller water system. The process water flows ina serial circuit through the heat exchangers and chilled water flows ina parallel circuit through the heat exchangers, and the two watersystems never come into physical contact with each other. All of thewater is made available to the mandrel water system. A pressure reliefvalve limits the system pressure. The water not used the mandrel systemis diverted to the holding tank, which cools the process water in theholding tank. The water is pumped through the inside of the mandrel barthrough the inner water tube (e.g., inner tube 350 of FIGS. 6 and 8) tothe mandrel bar tip and returns down the length of the outer space ofthe inside of the mandrel bar as discussed with respect to FIGS. 6 and8. As the water has circulated through the mandrel cooling system, it isreturned into the holding tank which is the other source of cooling theprocess water to the holding tank. Preferably at no time is the mandrelprocess water supply interrupted while the press is running. The presswater system is supplied water from the holding tank. Flow and pressureis regulated by a relief valve with excess water being returned to theholding tank. The press water is pumped to a manifold where it is routedto cool various components of the system, including the rotating die, bymeans of a high velocity water spray from a cooling ring which water isrouted to cool the gear box hydraulic oil before going to cool the die.The centering insert 152, by means of a constant flow through acentering insert holder, the billets through a flood system as it entersthe Inconel, and the tube being extruded by use of the quench tube whichspray quenches the tube. The quench tube is housed inside the spindle.The process water from the above operations returns back to the holdingtank.

FIG. 10 shows a perspective view of the mandrel grip 106 of FIG. 1according to certain embodiments. The mandrel grip 106 includes a frontplate 502 and back plate 504 separated by a spacer 506. Within the frontplate 502 is a cut-out gripping portion 508 and a top grip 510 andbottom grip 512, although it will be understood that alternatively, oradditionally, in certain embodiments the grips 510, 512 could bepositioned side-to-side rather than top-to-bottom within the mandrelgrip 106. The mandrel grip 106 also includes a cylinder 514 and pistonrod 515 coupled to a cylinder mount 516. The cylinder 514 operates tocontrol the gripping and ungripping of the top grip 510 and bottom grip512 with respect to the mandrel bar 100.

FIGS. 11 and 12 show front elevation views of the mandrel grip 106 ofFIG. 10 in a closed or engaged gripping position (FIG. 11) and anon-gripping or open position (FIG. 12). As shown in FIG. 11, forexample, the top grip 510 and the bottom grip 512 are in a grippingposition and engaged about a mandrel bar portion 518, which is theportion of the mandrel bar to which the grippers 510, 512 grip. When themandrel grip 106 is in an open or non-gripping position, as shown inFIG. 12, the top grip 510 and the bottom grip 512 are displaced from oneanother relative to the gripping position and are thereby displaced fromthe mandrel bar portion 518, such that there is clearance along themandrel portion 518, and within the gripping cutout 508, for a billet topass therethrough.

In certain embodiments, the top grip 510 and the bottom grip 512 arestructured to mate with a corresponding portion of a mandrel bar, suchas the mandrel bar portion 518 of the mandrel bar 540. FIG. 13 shows aschematic view of a mandrel bar 540 having portions 518 that may beshaped or otherwise configured to mate with the top grip 510 and thebottom grip 512 of the mandrel grip 106. The particular shape of themandrel bar portions 518 may aid the mandrel grip 106 in forming andmaintaining a secure grip of the mandrel bar 540 to prevent the mandrelbar 540 from rotating or otherwise moving or displacing during operationof the press system when the mandrel bar 540 is gripped by the mandrelgrip 106. As shown in FIG. 13, for example, the two grip portions 518may correspond to the portions of the mandrel bar that interface withthe two mandrel grips 106, 108 of the extrusion press system 10 of FIG.1.

A perspective view of the portion 518 of the mandrel bar 540 is shown inFIG. 14. The mandrel bar portion 518 is shaped to mate with a mandrelgrip such as mandrel grip 106 and includes a rounded circumferenceportion 550 and various straight edges 552 and 554 that mate with thetop and bottom grips of a mandrel grip. The mandrel portion 518 alsoincludes various insets or cut-outs 556 and 558 shaped to mate withcomplementary grippers. As shown in FIG. 14, the mandrel portion 518 ishollow and includes an inner surface 540 a for receiving an inner tubesuch as the inner tube 350 discussed above with respect to FIGS. 6 and8.

In certain embodiments, the mandrel bar extends along the length of theextrusion press system 10, terminating at a mandrel bar tip positionedwithin the rotating die. The mandrel bar may have a substantiallycontinuous cross-section along its length or may have portions thereof(such as portions 342, 348, 518 and mandrel bar sleeve 360) shaped forinterfacing with components of the press system such as the fluid clamps102, 104 and the mandrel grips 106, 108. In certain embodiments, themandrel bar may be modular and may comprise a plurality of attachablesections that together form the mandrel bar for use with an extrusionpress system. For example, the mandrel bar 540 of FIG. 13 may beconfigured to attach to other mandrel bars, or sections of mandrel bars,such as the mandrel bar 340 of FIG. 6, which shows a portion of amandrel bar 340 used to couple with fluid clamps. In order to attachthese modular portions of a mandrel bar together, the mandrel bar 540 isprovided with ends 542 and 544 that receive the complementary ends ofanother mandrel bar.

FIG. 15 shows a perspective view of the press-ram assembly 141 of FIG. 1having guide members for guiding the press-ram assembly 141 along thetie rods 124 according to certain embodiments. As shown in FIG. 15, forexample, the first press-ram platen 130 and the second press-ram platen140 include guide members 600 and 610, respectively. The guide member600 of press-ram platen 130 has hanging plates 602 coupled to bearings604, which bearings 604 are configured to move the press-ram 130 alongtie rods such as tie rods 124 of FIG. 1. The guide member 610 ofpress-ram platen 140 also includes hanging plates 612 and variousbearings 614 configured to move the press-ram 140 along tie rods 124.The hanging plate 614 of guide member 610 is positioned above where thetie rods 124 are located and the hanging plate 602 of guide member 600is located below the position at which the tie rods 124 are located.These guide members 600, 610 allow the press-ram platens 130, 140 tomove along the tie rods 124 as the extrusion process operates such thatthe press-ram platens 130, 140 can grip and advance billets into therotating die and then retraction to begin the next cycle.

FIG. 16 shows a perspective view of the press-ram platen 130 of FIG. 1according to certain embodiments. FIGS. 17-19 show front, side, and rearelevation views, respectively, of the press-ram platen 130 of FIG. 16.The press-ram platen 130 includes a grip mounting plate 620 and firstand second billet gripper link arms 622 and 624 that are coupled to acylinder 626 about a pivot 625. The cylinder 626 operates to move thefirst and second link arms 622, 624 with respect to one another andabout the pivot 625. The grip mounting plate 620 is coupled to the linkarms 622, 624 and separated by a spacer 621 therebetween. As shown inFIG. 19, first and second grips 630, 632 are mounted to the first andsecond link arms 622, 624, and are supported by a bottom mount 634 andtop mount 635. In certain embodiments, the gripping surfaces 630 a, 632a of the first and second grips 630, 632, can have a serrated orotherwise textured surface for improving the frictional contact betweenthe gripping surfaces 630 a, 632 a and a gripped billet.

FIG. 20 shows a perspective view of the press-ram platen 140 of FIG. 1according to certain embodiments. FIGS. 21-23 show front, side, and rearelevation views, respectively, of the press-ram platen 140 of FIG. 20.The press-ram platen includes a grip mounting plate 640 and first andsecond billet gripper link arms 642 and 644 that are coupled to acylinder 646 about a pivot 645. The cylinder 646 operates to move thefirst and second link arms 642, 644 with respect to one another andabout the pivot 645. The grip mounting plate 640 is coupled to the linkarms 642, 644 and separated by a spacer 641 therebetween. As shown inFIG. 23, first and second grips 650, 652 are mounted to the first andsecond link arms 642, 644, and are supported by a bottom mount 654 andtop mount 655. In certain embodiments, the gripping surfaces 650 a, 652a of the first and second grips 650, 652 can have a serrated orotherwise textured surface to increase the frictional contact betweenthe gripping surfaces 650 a, 652 a and a gripped billet.

In certain embodiments, one or both of the first and second press-rams130, 140 may include centering links. For example, centering links maybe coupled to the link arms 622, 624 and/or the cylinder 626 of thefirst press-ram 130 for synchronizing movement of the respective arms ofthe press-ram 130 about the pivot 625. This prevents, for example,operation of the cylinder 626 from extending one arm about the pivotpoint 625 while the other arm remains still. When the movement of thearms 622, 624 is synchronized about the pivot 625 using the centeringlinks, both arms move together when gripping and releasing the billets.

A billet pressed through the die 160 is extruded by heat generated fromfriction and forces applied to the billet by an interior surface of thedie 160. Before a billet is pressed into the die 160, the die and thecentering insert 152 are pressed together to form a sealed matinginterface for extrusion, and this orientation is shown in FIG. 24.During extrusion, the die 160 rotates while billet 702 is pressedthrough the die. The billet 702 is held by grippers on the centeringinsert 152, which does not rotate, and thus the billet 702 does notrotate as it enters the rotating die 160 at the entrance 716 to the die.The rotation of the die 160 creates friction with the outer surface ofthe non-rotating billet 702 as it is pressed through the die, and thefriction heats the billet 702 to a temperature sufficient for the billetmaterial to deform. For example, a metal billet may be heated by thefriction to a temperature grater than 1000° F. for deformation. Thetemperature requirements of different materials and different metals mayvary, and billet temperatures less than 1000° F. may be suitable in someapplications. In contrast to other extrusion systems, the extrusionassembly in FIG. 24 does not require pre-heating of billets beforeextrusion, as the rotation of the die 160 and the friction created bycontact with the non-rotating billet 702 provide energy that heats thebillet to a deformable temperature.

While the billet 702 and centering insert 152 do not rotate during theextrusion process, the die 160 and base 700 to which the body of the dieis connected are rotated by a motor-driven spindle. As the billet 702 isadvanced through the centering insert 152, it passes through theentrance 716 of the die 160 and contacts an interior surface of the die,shown in more detail in FIGS. 25-28. In addition to the die 160 and theinner surface details shown in FIGS. 24-28, other die designs or innersurface profiles may be implemented in a rotating die. For example, adie assembly for an extrusion system may be the die assembly describedin copending, commonly-assigned U.S. patent application Ser. No.[______] (Attorney Docket No. 109965-0005-101), filed concurrentlyherewith, and entitled “EXTRUSION PRESS DIE ASSEMBLY,” the disclosure ofwhich is hereby incorporated by reference herein in its entirety. Atorsional force is applied to the outer surface of the billet 702 due tothe interference contact between the rotating die 160 and the billet702. The grippers on the centering insert 152 resist this torsionalforce and prevent the billet 702 from rotating before it enters the die160, creating friction and producing the energy that heats the billet702.

The interior surface of the die 160 exhibits a tapered profile thatnarrows the interior passage through the die 160 from the entrance 716to an exit 718. Thus, when force is applied to the billet 702 to pressthe billet through the die 160, the material of the billet 702 isextruded as the outer diameter of the material is forced to decrease topass through the interior of the die 160 from entrance 716 to exit 718.The dimensions of the die 160 and interaction between the interiorsurface of the die 160 and the billet 702 is described in more detailbelow with respect to FIGS. 25-28.

The cross section view of the die 160 in FIG. 25 shows the die 160 andthe centering insert 152 positioned for extrusion. While the die 160 isshown in FIG. 25 as a single, unibody component, the die may also becomposed of multiple die plates having bores and interior surfaces thatform the passage and inner surface of the die, as discussed below withrespect to FIG. 26. In this orientation, the opening 716 of the interiorpassage 720 in the die 160 is aligned with the centering insert 152 toreceive a billet pressed through the opening 722 of the centering insert152 and into the die 160 along the center axis 724 of the interiorpassage 720. The inner surface 726 narrows the interior passage 720 fromthe largest diameter of the passage at the opening 716 to the smallestdiameter at the exit 718, and the narrowing of the passage 720 causesthe narrowing deformation and extrusion of a billet pressed into the die160 during operation. The extrusion requires friction energy to beproduced at the interface of the inner surface 726 to heat the billet,and the energy is provided by the interaction of the rotating surface726 and the non-rotating billet pressed into the die.

FIG. 26 shows the die 160 in an alternate construction of die platesthat form the body of the die 160. The die 160 in FIG. 26 includes asteel end holder 706, an entry plate 708, a first intermediate plate710, a second intermediate plate 712, and an exit plate 714. Each plateincludes a bore through the center of the plate, and the bores arestacked adjacent one another to form the interior passage 720 of the die160. The interior surfaces surrounding the bores of the plates areangled to form the profile of the inner surface 726 and narrow theinterior passage 720 from the entrance 716 to the exit 718. Onepotential advantage of using the plate construction is the ability toexchange individual plates when areas of the inner surface 726 begin towear, rather than having to replace the full die 160. To reduce theeffects of wear on the plates, each plate may also be constructed fromtwo different materials, with one material outlining the center bore ofthe plate and forming the inner surface 726 and a second materialforming an outer perimeter of the plate. Wear-reducing materials, suchas ceramic materials or steel, may be used to form the bore perimeter,or a consumable material may be used and periodically replaced. Becausethe centering insert 152 does not rotate when the die 160 rotates, thematerial surrounding the bore in steel end holder 706 and forming thefront face 738 of the die 160 may be the same as or similar to thematerial of the centering insert 152 to reduce the effect of wear as thetwo materials come into contact during extrusion.

To reduce the cost-increasing effect of the friction wear on each of theplates in the die 160, the plates may be designed to focus the wear onone or more plates that are replaced more often than the remainingplates. Such a design may allow the die to be operated by producingmultiple copies of a single plate and a single plate for the rest of theplates in the stack. For example, in the stack shown in FIG. 26, thesecond intermediate plate 712 exhibits a non-uniform surface profilearound the center bore through the plate. The inner surface of plate 712includes a first portion 740 that is angled at a sharper angle than theother inner surfaces in the die plate stack and a second portion 742that is angled similarly to other inner surfaces in the stack. The sharpangle of the first portion 740 creates a greater decrease in diameter atthat section of the inner surface relative to the other plates in thestack, and thus creates a greater friction force and potential for wearat the first portion 740. This wear may be decreased by positioning acorresponding angled portion of a mandrel bar within the passage 720near the portion 740 to further reduce costs created by the need toreplace the plate 712. In certain implementations, the angle of the boreperimeter on each plate may increase from the back face of first plateto the front face of the next plate towards the exit of the die. Forexample, in FIG. 26, the angle of each inner perimeter near the frontface of each plate is greater than the angle of the inner surface nearthe back face of the adjacent plate positioned nearer the entrance ofthe die. This design may be desired, for example, to focus work andstress towards the exit of the die 160, and may result in a need toreplace plates near the exit 718, for example plates 714 and 712, moreoften than plates that are nearer the entrance 716.

In addition to focusing work and stress within the die 160, mechanicaland thermal properties of the billet materials may dictate the numberand design of plates in a die assembly. For example, a billet materialhaving high thermal conductivity may heat up to a deformable temperaturemore quickly than a material having a low thermal conductivity, and thusa shorter die with fewer plates may be used for the high conductivitymaterial. In addition, the tapering angles of the inner surface of a diemay be greater for the high conductivity material as a result of thequicker heating of the billet. In other implementations, dies of equalsize having the same number of plates may be used, and the taperingangles of the dies may differ to accommodate the different thermalproperties and heat the billets to a deformable temperature while stillfocusing work and wear to a desired area of the die surface and thesurface of a mandrel tip within the die, or while spreading the work andwear over the surfaces.

Whether a unibody or die plate stack die is implemented, a billetpressed through the die 160 produces an extruded tube product throughexit 718 of the die 160 having an outer diameter that is similar to thediameter d1, the diameter at the narrowest portion of interior passage720. The inner diameter of the extruded product is selected by advancingthe mandrel bar 100 into the die 160 with a mandrel bar tip, such asmandrel bar tip 800, having an end dimension selected to create theinner diameter of the tube product at the end of the mandrel bar 100.

FIG. 27 shows the die 160 with the mandrel bar 100 and mandrel bar tip800 advanced through the centering insert 152 and into the centerpassage 720 of the die 160. As discussed above with respect to FIG. 1,gripping elements in an extrusion press system may be used to hold themandrel bar 100 and in the orientation shown in FIG. 27 and to resistrotation while the die 160 is rotated and a billet passes over themandrel bar 100.

FIG. 28 shows the die and mandrel bar configuration of FIG. 27 as thebillet 702 is passed through the die 160 and extruded to form tubing728. During extrusion, the die 160 is rotated while the mandrel bar 100and centering insert 152 are held stationary. The billet 702 is pressedinto the die 160 in the direction of arrow A and contacts the interiorsurface 726 of the die 160 at a first contact point 730. Theinterference contact between the interior surface 726 and the billet 702begins at the contact point 730 and generates the energy that heats thebillet 702 to a plastic deformable temperature. The design of the innersurfaces and the profile of the interior die surface may differ fordifferent applications, and in particular for the extrusion of differentmaterials. Depending on the material properties of billets used forextrusion, for example heat transfer properties that may affect theheating of the billets during extrusion, the inner profile of die platesin a die body may be varied to focus or spread work and wear over thedie plates. In addition, the die rotation speed may be varied for aparticular extrusion to increase the efficiency of the die and avoidexceeding material properties of the billets. For example, a dierotation speed between about 200 rpm and about 1000 rpm may be used. Incertain implementations, a slower rotation speed, for example about 300rpm, may be desired to avoid applying a high level of torsional sheer toa billet while still heating the billet to a sufficient temperature fordeformation. A faster speed, for example about 800 rpm, may be used fora material that is not adversely affected by a higher torsional sheer orthat requires more energy, and thus greater friction, to heat to adeformation temperature. In other implementations, die rotation speedsin excess of 100 rpm may be desired for extrusion.

As the billet 702 is advanced over the middle portion 732 of the mandrelbar tip 800, the taper of the interior surface 726 applies a compressionforce to the outer surface of the billet 702 that presses the billet 702inwards towards the mandrel bar tip 800. Because the billet 702 is in aplastic deformation state, the material in the billet extrudes in thedirection of end portion 734 of mandrel bar tip 800 as the die 160decreases the outer diameter of the billet 702 from the originaldiameter d2 to a final outer diameter d3. When the billet 702 reachesthe middle portion 732, the taper of the mandrel bar tip 800 towards theend portion 734 causes the inner diameter of the billet 702 to extrudeand decrease from the original diameter d4 as the billet advancesfurther over the mandrel bar tip 800. The tapered surface of the mandrelbar tip 800 in the middle portion 732 may be positioned near a sharpangled portion of the inner surface 726, for example near a first sharpangle portion 740, as discussed above with respect to secondintermediate plate 712. This orientation positions the tapered middleportion 732, and the area in which the inner diameter of a billetpassing over the mandrel bar tip 800 is decreased, in the same locationas the greatest compression force produced by inner surface 726 over die160.

When the extruding billet 702 reaches the end portion 734, the innerdiameter of the billet is reduced from the original diameter d4 to thefinal diameter d5 of the end tubing product 728. As the billet 702passes over the end portion 734, the outer diameter of the billet 702continues to decrease to the final outer diameter d3 when the extrudedtubing product 728 exits the die at exit 718. At the point of exit, theformation of the extruded product 728 is complete. Due to the frictionand heating within the die 160, the product 728 is at a heightenedtemperature upon exit from the die 160, and a cooling element may beapplied to prevent further deformation or increase operational safety ofthe extrusion press, eliminate the escape of extruded material, ormaintain desired material characteristics. A bore 736 in the base plate700 is shown in FIG. 28 with a diameter larger than the diameter of thedie exit 718. This configuration may be preferable in order to allowcooling elements and cooling fluid to reach into the base plate 700 andcontact the extruded product 728 as soon as it exits the die 160 forearlier cooling. After the product 728 exits the base plate 700 andpasses through a cooling system, the extrusion process is complete, andthe product 728 may be gathered for post-processing.

FIGS. 29 and 30 show a perspective view and a top plan view,respectively, of mandrel bar tips according to certain embodiments.Mandrel bar tip 800 includes a connector 802 that couples with a mandrelbar to form the mandrel bar tip of the mandrel bar. The mandrel bar tip800 also includes various extrusion contact surfaces 804 that contactthe inner surface of a hollow billet as the billet passes over themandrel bar tip 800, which is positioned within a rotating die. Themandrel bar tip 800 has a terminal contact surface 806 with a diameterD1 that sets the inner diameter of the extruded tubing. During theextrusion process, the rotating die rotates against the billet andthereby generates heat, which softens the billet to allow for plasticdeformation of the billet. During operation of the extrusion presssystem 10, the combination of the rotating die 160 and the mandrel bartip 800 causes the plastic deformation zone of the billet to generallyoccur in the plastic deformation zone 808 of the mandrel bar tip 800.

The mandrel bar tip 800 may have any suitable diameter along theextrusion surfaces 804 as well as the terminal contact surface 806. Forexample, in certain embodiments, as shown by mandrel bar tip 820, theterminal contact surface 826 may have a setting diameter D2 that isrelative larger than the setting diameter D1 of mandrel bar tip 800. Incertain embodiments, each of the contact surfaces 804 of the mandrel bartip 800 may correspond to the respective profile of the various dieplates within the rotating die.

FIG. 31 shows a flowchart for pre-processing a billet for use in theextrusion press system 10 of FIG. 1 according to certain embodiments. Atstep 1010, the billet is cast using any suitable casting process. Forexample, casting a billet may include the use of a casting furnace forproducing a billet of desired proportions. The cast billet may then bestraightened using a roll straightening process at step 1020, followedby machining the rolled billet at step 1030. Machining the rolled billetincludes, for example, clearing any rough edges or surfaces of thebillet. At step 1040, the machined billet may be strain hardened andsized. Strain hardening may include compressing the billet to inducestrain hardening effects that allow the billet to withstand the pressingforces exerted onto the billet during the extrusion process bypress-rams (e.g., press-ram platens 130, 140 of FIG. 1), as well as therotation and shear stresses induced by a rotating die (e.g., rotatingdie 160 of FIG. 1). At step 1050 the billet may again be straightenedusing any suitable straightening device. At step 1060 the billet endsare trimmed. The trimming allows for removing imperfections or otherdeformations at the ends of the billet, for example, that may have beenintroduced during the prior processing steps or during casting. Thebillet may then be cleaned at step 1070 using any suitable cleaningsolution such as a water soluble degreasing solution or combination ofcleaning solutions. At step 1080 the inner diameter of the billet may belubricated with any suitable lubrication fluid including graphitelubricants, petroleum-based composites or non-petroleum synthesizedcompounds, any other suitable lubrication fluid or combinations thereof.

FIG. 32 shows a flowchart for pre-processing a mandrel bar tip, such asthe mandrel bar tip 800 or 820 of FIGS. 28 and 29, for use in theextrusion press system 10 of FIG. 1 according to certain embodiments. Atstep 1110, the mandrel bar tip may be heated using any suitable heatingprocess. For example, the mandrel bar tip may be placed in a furnace orheated with a blowtorch until the mandrel bar tip is greater thanapproximately 1,000 degrees Fahrenheit. Following this heat treatment,at step 1120, the mandrel bar tip may be quenched in lubricant andagitated to ensure a consistent deposit of the lubricant. In certainembodiments the lubricant is a graphite lubricant, although any othersuitable lubricant or combinations thereof may be used. At step 1130,the mandrel bar tip is allowed to cool after quenching. At step 1140,any excess lubricant is removed from the mandrel bar tip. The mandrelbar tip is then be reheated at step 1150 to greater than approximately1,000 degrees Fahrenheit and quenched in lubricant and agitated at step1160 to ensure a consistent deposit of the lubricant. In certainembodiments, the mandrel bar tip is quenched using a second lubricantthat is different than the first lubricant used in step 1120. Forexample, the lubricant used in step 1120 may be a graphite lubricant andthe lubricant used in step 1160 may be a petroleum-based composite ornon-petroleum synthesized compound, or any other suitable lubricant thatis different than the first lubricant. In certain embodiments, thelubricant used in step 1160 may be the same as that used in step 1120.At step 1170, the mandrel bar tip is allowed to cool after the quenchingstep 1160. In certain embodiments, after completing process step 1170,the process steps 1150, 1160, and 1170 may be repeated. In suchembodiments, the lubricant used in the repeated quenching step may bethe same as that used in the prior step 1160, which lubricant may be thesame as or different than that used in the first quenching step 1120.

FIGS. 33-36 show various flowcharts depicting processes for operating anextrusion press system, such as the extrusion press system 10 of FIG. 1,according to certain embodiments. Steps 1210 through 1240 depict certainexemplary steps of the billet delivery subsystem 20 of the extrusionpress system. Step 1250 depicts certain exemplary steps of the extrusionsubsystem 40 of the extrusion press system, and step 1260 depictscertain exemplary steps of the quenching subsystem 60 of the extrusionpress system. It will be understood that the steps of the flowcharts ofthis disclosure are merely illustrative. Any of the steps of theflowcharts may be modified, omitted, or rearranged, two or more of thesteps may be combined, or any additional steps may be added, withoutdeparting from the scope of the present disclosure.

Process 1200 begins at step 1210, where one or more billets are loadedabout the receiving end 100 a of the mandrel bar near the first orupstream fluid clamp 102. Each of the billets of the present disclosureis hollow along the length of the billet, which allows the billets to beplaced onto the stationary mandrel bar 100 such that the billet movesand is transported along and about the mandrel bar 100. In certainembodiments, the billet delivery subsystem 20 of the extrusion presssystem 10 may include a billet delivery table with a plurality ofbillets prepped for loading onto the extrusion press system 10. Thebillets may be loaded automatically by an automated process or may beloaded by hand. Once loaded, the billets may be transported along themandrel bar by a billet feed track assembly such as the track assembly110 shown in FIG. 2, which includes a track 202 that intermittentlymoves depending on the position of particular billets relative to thefluid clamps 102, 104 and the mandrel grips 106, 108.

At step 1220 the billets are transported along the mandrel bar andthrough the fluid clamps, which when engaged to the mandrel bar delivercooling fluid to the mandrel bar tip. At any given time, at least one ofthe fluid clamps is preferably clamped to or otherwise engaged with themandrel bar to provide a continuous or substantially continuous deliveryof cooling fluid to the mandrel bar. The steps for passing one or morebillets through the respective fluid clamps of the extrusion presssystem are shown in FIG. 34. For example, at step 1400, one or morebillets are transported to a first upstream fluid clamp such as fluidclamp 102 of extrusion press system 10. The PLC system determineswhether the first fluid clamp is engaged with the mandrel bar atdecision block 1402. If the first fluid clamp is engaged with themandrel bar, the PLC system then determines whether the second fluidclamp is engaged with the mandrel bar at decision block 1404. In certainembodiments, both fluid clamps may be engaged with the mandrel bar whenbillets are not being passed through the fluid clamps. If the secondfluid clamp is engaged, then at step 1410 the first fluid clamp isdisengaged. However, if the second fluid clamp is not engaged, at step1404, the PLC system determines that the second fluid clamp istransporting billets therethrough and waits for the billets to clear thesecond fluid clamp at step 1406. Then at step 1408 the second fluidclamp is engaged and the process continues to step 1410 where the firstfluid clamp is disengaged. After the first fluid clamp is disengaged atstep 1410, or if the first fluid clamp was already determined to bedisengaged at decision block 1402, the process continues to step 1412where one or more billets are advanced through the first fluid clamp.While the first fluid clamp is disengaged to allow the billets to passtherethrough, the second fluid clamp is engaged to the mandrel bar anddelivering cooling fluid to the mandrel bar. After a desired number ofbillets have been advanced through the first fluid clamp, the firstfluid clamp is engaged with the mandrel bar at step 1414 and the billetsare transported to the second fluid clamp at step 1420.

The process 1220 with respect to the second fluid clamp is substantiallysimilar to that performed by the PLC system for the first fluid clampand is also shown in FIG. 34. At step 1420, one or more billets aretransported to a second, downstream fluid clamp such as fluid clamp 104of extrusion press system 10. The PLC system determines whether thesecond fluid clamp is engaged with the mandrel bar at decision block1422. If the second fluid clamp is engaged with the mandrel bar, the PLCsystem then determines whether the first fluid clamp is engaged with themandrel bar at decision block 1424. In certain embodiments, both fluidclamps may be engaged with the mandrel bar when billets are not beingpassed through the fluid clamps. If the first fluid clamp is engaged,then at step 1430 the second fluid clamp is disengaged. However, if thefirst fluid clamp is not engaged, at step 1424, the PLC systemdetermines that the first fluid clamp is transporting billetstherethrough and waits for the billets to clear the first fluid clamp atstep 1426. Then at step 1428 the first fluid clamp is engaged and theprocess continues to step 1430 where the second fluid clamp isdisengaged. After the second fluid clamp is disengaged at step 1430, orif the second fluid clamp was already determined to be disengaged atdecision block 1422, the process continues to step 1432 where one ormore billets are advanced through the second fluid clamp. While thesecond fluid clamp is disengaged to allow the billets to passtherethrough, the first fluid clamp is engaged to the mandrel bar anddelivering cooling fluid to the mandrel bar. After a desired number ofbillets have been advanced through the second fluid clamp, the secondfluid clamp is engaged with the mandrel bar at step 1434.

Returning to process 1200 of FIG. 33, at step 1230 the billets aretransported along the mandrel bar and through mandrel grips, which whenengaged to the mandrel bar secure the mandrel bar in place and preventrotation of the mandrel bar. At any given time, at least one of themandrel grips is preferably clamped to or otherwise engaged with themandrel bar. The steps for passing one or more billets through therespective mandrel grips of the extrusion press system are shown in FIG.35. For example, at step 1500, one or more billets are transported to afirst upstream mandrel grip such as mandrel grip 106 of extrusion presssystem 10. The PLC system determines whether the first mandrel grip isengaged with the mandrel bar at decision block 1502. If the firstmandrel grip is engaged with the mandrel bar, the PLC system thendetermines whether the second mandrel grip is engaged with the mandrelbar at decision block 1504. In certain embodiments, both mandrel gripsmay be engaged with the mandrel bar when billets are not being passedthrough the mandrel grips. If the second mandrel grip is engaged, thenat step 1510 the first mandrel grip is disengaged. However, if thesecond mandrel grip is not engaged, at step 1504, the PLC systemdetermines that the second mandrel grip is transporting billetstherethrough and waits for the billets to clear the second mandrel gripat step 1506. Then at step 1508 the second mandrel grip is engaged andthe process continues to step 1510 where the first mandrel grip isdisengaged. After the first mandrel grip is disengaged at step 1510, orif the first mandrel grip was already determined to be disengaged atdecision block 1502, the process continues to step 1512 where one ormore billets are advanced through the first mandrel grip. While thefirst mandrel grip is disengaged to allow the billets to passtherethrough, the second mandrel grip is engaged to the mandrel bar.After a desired number of billets have been advanced through the firstmandrel grip, the first mandrel grip is engaged with the mandrel bar atstep 1514 and the billets are transported to the second mandrel grip atstep 1520.

The process 1230 with respect to the second mandrel grip issubstantially similar to that performed by the PLC system for the firstmandrel grip and is also shown in FIG. 35. At step 1520, one or morebillets are transported to a second, downstream mandrel grip such asmandrel grip 108 of extrusion press system 10. The PLC system determineswhether the second mandrel grip is engaged with the mandrel bar atdecision block 1522. If the second mandrel grip is engaged with themandrel bar, the PLC system then determines whether the first mandrelgrip is engaged with the mandrel bar at decision block 1524. In certainembodiments, both mandrel grips may be engaged with the mandrel bar whenbillets are not being passed through the mandrel grips. If the firstmandrel grip is engaged, then at step 1530 the second mandrel grip isdisengaged. However, if the first mandrel grip is not engaged, at step1524, the PLC system determines that the first mandrel grip istransporting billets therethrough and waits for the billets to clear thefirst mandrel grip at step 1526. Then at step 1528 the first mandrelgrip is engaged and the process continues to step 1530 where the secondmandrel grip is disengaged. After the second mandrel grip is disengagedat step 1530, or if the second mandrel grip was already determined to bedisengaged at decision block 1522, the process continues to step 1532where one or more billets are advanced through the second mandrel grip.While the second mandrel grip is disengaged to allow the billets to passtherethrough, the first mandrel grip is engaged to the mandrel bar.After a desired number of billets have been advanced through the secondmandrel grip, the second mandrel grip is engaged with the mandrel bar atstep 1534.

Returning to process 1200 of FIG. 33, at step 1240 the billets aregripped and then advanced using press-rams. The press-rams provide asubstantially constant pushing force against the gripped billets in adirection toward the rotating die. The PLC system controls the rate atwhich the press-rams operate and thereby controls the entry of billetsinto the rotating die. The steps for grabbing and advancing billetsusing press-rams of the extrusion press system are shown in FIG. 36. Forexample, at step 1600 a billet is gripped by a first, upstream press-ramsuch as press-ram 130 of the extrusion press system of FIG. 1. The firstpress-ram is advanced toward a second, downstream press-ram at step1602. The PLC system determines whether the second press-ram has beenretracted to a receiving position to receive the billet at decisionblock 1604. If the second press-ram is not in position then at step 1606the first press-ram continues advancing the billet until the secondpress-ram is in position. If the second press-ram is in position, atstep 1604, then the billet is gripped by the second press-ram at step1608. The first and second press-rams continue advancing the billettogether at step 1610. This may ensure that a continuous orsubstantially continuous pushing force is applied to the billet in thedirection of the rotating die. At step 1612 the first press-ram releasesthe billet (while the second press-ram continues to advance the billet)and at step 1614 the first press-ram is retracted to a receivingposition to thereby grab a subsequent billet. This arm-over-arm processallows the rotating die to receive a constant stream of billets at adetermined feed rate. Prior to the first press-ram gripping the billetat step 1600, the feed track assembly may continuously index the trackto minimize the gaps between adjacent billets queued to be advanced bythe press-rams.

At step 1250 the billets are extruded to form an extruded material. Thepress-rams of step 1240 advance billets through a centering insert(e.g., centering insert 152 of FIG. 1) having a plurality of notchesthat prevent the billets from rotating prior to entry of the billetsinto the rotating die. Once a billet enters the rotating die, the diesimultaneously heats the billet and sets the outer diameter of thebillet as the billet is extruded to form the extruded material. Themandrel bar is positioned to place the mandrel bar tip within therotating die. The mandrel bar tip sets the inner diameter of theextruded material. The position of the mandrel bar with respect to thedie can be controlled by the PLC system. The PLC system can also controlthe rotation speed of the rotating die using a motor 170 coupled to thespindle 172.

At step 1260 the extruded material is quenched as it exits the rotatingdie. This step includes rapidly cooling the extruded material byspraying cooling fluid such as water, or any other suitable coolingfluid, at a high velocity from a quench tube onto the extruded material.Despite the temperatures generated during the extrusion process of step1250, upon exiting the quench tube, the extruded material is relativelycool enough to the touch that it can be handled without causing burns.Furthermore, in certain embodiments, nitrogen gas, or another suitableinert gas, is delivered to the interior of the extruded material as thematerial exits the rotating die. For example, nitrogen gas may bedelivered to the interior of extruded tubing using a cap placed on thetubing as it exits the rotating die. Injecting gaseous or liquidnitrogen into the rotating die assembly, or the interior of the extrudedmaterial itself, can minimize oxide formation by displacing theoxygen-laden air.

It will be understood that as one or more billets proceed through theprocess 1200 thus described, other billets may be advancing through theextrusion press system at any of the other steps of the process 1200.For example, as a first set of billets, including one or more billets,is transported through the fluid clamps at step 1220, another set ofbillets, including one or more billets, may be contemporaneously loadedonto the mandrel bar at step 1210 or transported through mandrel gripsat step 1230 or any other step appearing in process 1200. In this waythe extrusion press system is operable to continuously feed a pluralityof billets into a rotating die to extrude the billets to form anextruded material.

FIG. 37 shows a block diagram of a programmable logic control system foroperating the extrusion press system of FIG. 1 according to certainembodiments. As discussed above, the extrusion press system 10 comprisesthe functional subsystems of a billet delivery subsystem 20, anextrusion subsystem 40, and a cooling or quenching subsystem 60.Operation of certain components in any one or more of these subsystems20, 40, 60 may be controlled by the PLC system 1700. Various operationalsteps of the subsystems 20, 40, 60 are described above with reference toprocess 1200 of FIGS. 33-36.

Instructions for carrying out the methods of this disclosure forextruding a material may be encoded on a machine-readable medium, to beexecuted by a suitable computer or similar device to implement themethods of the disclosure for programming or configuring PLCs or otherprogrammable devices with a configuration as described above. Forexample, a personal computer may be equipped with an interface to whicha PLC can be connected, and the personal computer can be used by a userto program the PLC using suitable software tools.

FIG. 38 shows a cross-section of a magnetic data storage medium 1800which can be encoded with a machine executable program that can becarried out by systems such as the aforementioned personal computer, orother computers or similar devices. Medium 1800 can be a floppy disketteor hard disk, or magnetic tape, having a suitable substrate 1801, whichmay be conventional, and a suitable coating 1802, which may beconventional, on one or both sides, containing magnetic domains (notvisible) whose polarity or orientation can be altered magnetically.Except in the case where it is magnetic tape, medium 1800 may also havean opening (not shown) for receiving the spindle of a disk drive orother data storage device.

The magnetic domains of coating 1802 of medium 1800 are polarized ororiented so as to encode, in manner which may be conventional, amachine-executable program, for execution by a programming system suchas a personal computer or other computer or similar system, having asocket or peripheral attachment into which the PLC to be programmed maybe inserted, to configure appropriate portions of the PLC, including itsspecialized processing blocks, if any, in accordance with the presentdisclosure.

FIG. 39 shows a cross-section of an optically-readable data storagemedium 1810 which also can be encoded with such a machine-executableprogram, which can be carried out by systems such as the aforementionedpersonal computer, or other computers or similar devices. Medium 1810can be a conventional compact disk read-only memory (CD-ROM) or digitalvideo disk read-only memory (DVD-ROM) or a rewriteable medium such as aCD-R, CD-RW, DVD-R, DVD-RW, DVD+R, DVD+RW, or DVD-RAM or amagneto-optical disk which is optically readable and magneto-opticallyrewriteable. Medium 1810 preferably has a suitable substrate 1811, whichmay be conventional, and a suitable coating 1812, which may beconventional, usually on one or both sides of substrate 1811.

In the case of a CD-based or DVD-based medium, as is well known, coating1812 is reflective and is impressed with a plurality of pits 1813,arranged on one or more layers, to encode the machine-executableprogram. The arrangement of pits is read by reflecting laser light offthe surface of coating 1812. A protective coating 1814, which preferablyis substantially transparent, is provided on top of coating 1812.

In the case of magneto-optical disk, as is well known, coating 1812 hasno pits 1813, but has a plurality of magnetic domains whose polarity ororientation can be changed magnetically when heated above a certaintemperature, as by a laser (not shown). The orientation of the domainscan be read by measuring the polarization of laser light reflected fromcoating 1812. The arrangement of the domains encodes the program asdescribed above.

A PLC 1700 programmed according to the present disclosure may be used inmany kinds of electronic devices. One possible use is in a dataprocessing system 1900 shown in FIG. 40. Data processing system 1900 mayinclude one or more of the following components: a processor 1901;memory 1902; I/O circuitry 1903; and peripheral devices 1904. Thesecomponents are coupled together by a system bus 1905 and are populatedon a circuit board 1906 which is contained in an end-user system 1907,which may include a terminal unit 1407 for operating an extrusion presssystem.

System 1900 can be used in a wide variety of applications, including asinstrumentation for an extrusion press system, or any other suitableapplication where the advantage of using programmable or reprogrammablelogic is desirable. PLC 1700 can be used to perform a variety ofdifferent logic functions. For example, PLC 1700 can be configured as aprocessor or controller that works in cooperation with processor 1901.PLC 1700 may also be used as an arbiter for arbitrating access to ashared resources in system 1900. In yet another embodiment, PLC 1700 canbe configured as an interface between processor 1901 and one of theother components in system 1900. It should be noted that system 1900 isonly exemplary. For example, in certain embodiment a user terminal maybe provided near the extrusion press system. In other embodiments, anetworked arrangement may be provided that may allow the user terminalto be remote from the extrusion press system.

FIG. 41 is a block diagram of a computing device 2200 used for carryingout at least some of the extrusion press logic processing describedabove according to certain embodiments. The computing device 2200comprises a PLC system such as PLC 1700, and at least one networkinterface unit 2204, an input/output controller 2206, system memory2208, and one or more data storage devices 2214. The system memory 2208includes at least one random access memory (RAM) 2210 and at least oneread-only memory (ROM) 2212. All of these elements are in communicationwith a central processing unit (CPU) 2202 to facilitate the operation ofthe computing device 2200. The computing device 2200 may be configuredin many different ways. For example, the computing device 2200 may be aconventional standalone computer or alternatively, the functions ofcomputing device 2200 may be distributed across multiple computersystems and architectures. The computing device 2200 may be configuredto perform some or all of the extrusion press logic processing describedabove, or these functions may be distributed across multiple computersystems and architectures. In the embodiment shown in FIG. 23, thecomputing device 2200 is linked, via communications network 2150 orlocal area network 2124 to third parties 2224 through the communicationsnetwork 2150.

The computing device 2200 may be configured in a distributedarchitecture, where databases and processors are housed in separateunits or locations. The computing device 2200 may also be implemented asa server located either on site at the extrusion press facility orexternal to the extrusion press facility. Some such units performprimary processing functions and contain at a minimum a generalcontroller or a processor 2202 and a system memory 2208. In such anembodiment, each of these units is attached via the network interfaceunit 2204 to a communications hub or port (not shown) that serves as aprimary communication link with other servers, client or user computersand other related devices. The communications hub or port may haveminimal processing capability itself, serving primarily as acommunications router. A variety of communications protocols may be partof the system, including, but not limited to: Ethernet, SAP, SAS™, ATP,BLUETOOTH™, GSM and TCP/IP.

The CPU 2202 comprises a processor, such as one or more conventionalmicroprocessors, and one or more supplementary co-processors, such asmath co-processors, for offloading workload from the CPU 2202. The CPU2202 is in communication with the network interface unit 2204 and theinput/output controller 2206, through which the CPU 2202 communicateswith other devices such as other servers, user terminals, or devices.The network interface unit 2204 and/or the input/output controller 2206may include multiple communication channels for simultaneouscommunication with, for example, other processors, servers or clientterminals. Devices in communication with each other need not becontinually transmitting to each other. On the contrary, such devicesneed only transmit to each other as necessary, may actually refrain fromexchanging data most of the time, and may require several steps to beperformed to establish a communication link between the devices.

The CPU 2202 is also in communication with the data storage device 2214.The data storage device 2214 may comprise an appropriate combination ofmagnetic, optical and/or semiconductor memory, and may include, forexample, RAM, ROM, flash drive, an optical disc such as a compact discand/or a hard disk or drive. The CPU 2202 and the data storage device2214 each may be, for example, located entirely within a single computeror other computing device; or connected to each other by a communicationmedium, such as a USB port, serial port cable, a coaxial cable, anEthernet type cable, a telephone line, a radio frequency transceiver orother similar wireless or wired medium or combination of the foregoing.For example, the CPU 2202 may be connected to the data storage device2214 via the network interface unit 2204.

The CPU 2202 may be configured to perform one or more particularprocessing functions. For example, the computing device 2200 may beconfigured, via the PLC, for controlling at least in part one or moreaspects of the billet delivery subsystem 20, extrusion subsystem 40, andquenching subsystem 60.

The data storage device 2214 may store, for example, (i) an operatingsystem 2216 for the computing device 2200; (ii) one or more applications2218 (e.g., computer program code and/or a computer program product)adapted to direct the CPU 2202 in accordance with the present invention,and particularly in accordance with the processes described in detailwith regard to the CPU 2202; and/or (iii) database(s) 2220 adapted tostore information that may be utilized to store information required bythe program.

The operating system 2216 and/or applications 2218 may be stored, forexample, in a compressed, an uncompiled and/or an encrypted format, andmay include computer program code. The instructions of the program maybe read into a main memory of the processor from a computer-readablemedium other than the data storage device 2214, such as from the ROM2212 or from the RAM 2210. While execution of sequences of instructionsin the program causes the CPU 2202 to perform the process stepsdescribed herein, hard-wired circuitry may be used in place of, or incombination with, software instructions for implementation of theprocesses of the present invention.

The term “computer-readable medium” as used herein refers to anynon-transitory medium that provides or participates in providinginstructions to the processor of the computing device (or any otherprocessor of a device described herein) for execution. Such a medium maytake many forms, including but not limited to, non-volatile media andvolatile media. Non-volatile media include, for example, optical,magnetic, or opto-magnetic disks, or integrated circuit memory, such asflash memory. Volatile media include dynamic random access memory(DRAM), which typically constitutes the main memory. Common forms ofcomputer-readable media include, for example, a floppy disk, a flexibledisk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM,DVD, any other optical medium, punch cards, paper tape, any otherphysical medium with patterns of holes, a RAM, a PROM, an EPROM orEEPROM (electronically erasable programmable read-only memory), aFLASH-EEPROM, any other memory chip or cartridge, or any othernon-transitory medium from which a computer can read.

Various forms of computer readable media may be involved in carrying oneor more sequences of one or more instructions to the CPU 2202 (or anyother processor of a device described herein) for execution. Forexample, the instructions may initially be borne on a magnetic disk of aremote computer (not shown). The remote computer can load theinstructions into its dynamic memory and send the instructions over anEthernet connection, cable line, or even telephone line using a modem. Acommunications device local to a computing device (e.g., a server) canreceive the data on the respective communications line and place thedata on a system bus for the processor. The system bus carries the datato main memory, from which the processor retrieves and executes theinstructions. The instructions received by main memory may optionally bestored in memory either before or after execution by the processor. Inaddition, instructions may be received via a communication port aselectrical, electromagnetic or optical signals, which are exemplaryforms of wireless communications or data streams that carry varioustypes of information.

The foregoing is merely illustrative of the principles of thedisclosure, and the systems, devices, and methods can be practiced byother than the described embodiments, which are presented for purposesof illustration and not of limitation. It is to be understood that thesystems, devices, and methods disclosed herein, while shown for use inextrusion press systems, may be applied to systems, devices, and methodsto be used in other manufacturing processes including, but not limitedto, cast-and-roll and heat treatment processes. Furthermore, thedisclosure could be implemented as a post-processing step of anothermanufacturing process, including other extrusion processes, or could beimplemented concurrently with another manufacturing process.

Variations and modifications will occur to those of skill in the artafter reviewing this disclosure. The disclosed features may beimplemented, in any combination and subcombination (including multipledependent combinations and subcombinations), with one or more otherfeatures described herein. The various features described or illustratedabove, including any components thereof, may be combined or integratedin other systems. Moreover, certain features may be omitted or notimplemented.

Examples of changes, substitutions, and alterations are ascertainable byone skilled in the art and could be made without departing from thescope of the information disclosed herein. All references cited hereinare incorporated by reference in their entirety and made part of thisapplication.

1-84. (canceled)
 85. A die for extruding a material, comprising: a diebody having: a passage defining an entrance and an exit, wherein thediameter of the exit is smaller than the diameter of the entrance; andan interior surface extending around the passage from the entrance tothe exit; and a base coupled to the die body, wherein rotation of thebase causes the die body to rotate.
 86. The die of claim 85, wherein thedie body is configured to receive a billet of material for extrusion,and the billet is not pre-heated before entering the die body.
 87. Thedie of claim 86, wherein rotation of the die body creates frictionbetween the interior surface and a billet advanced through the entranceand into the interior passage of the die body.
 88. The die of claim 87,wherein the friction heats the billet to a temperature that issufficient to cause deformation of the billet material.
 89. The die ofany of claims 85-88, wherein the die body is configured to receive amandrel tip through the entrance such that the mandrel tip ispositionable within the interior passage of the die body.
 90. The die ofclaim 89, wherein the interior surface of the die comprises an angledportion configured to be positioned near a corresponding tapered outersurface of the mandrel tip.
 91. The die of claim 89 or 90, wherein thedie body is configured to receive a billet pressed through the interiorpassage of the die body to form an extruded product, the extrudedproduct having an outer diameter corresponding to the diameter of theexit of the die body and an inner diameter corresponding to a diameterof the mandrel tip.
 92. The die of any of claims 85-91, wherein the diebody comprises a plurality of die plates coupled together to form astack.
 93. The die of claim 92, wherein each die plate has a circularbore through the center of the plate, and perimeters of the bores formthe interior surface in the die body.
 94. The die of claim 93, whereinthe perimeters of the bores are angled at different angles with respectto an axis extending through the die body from the entrance to the exit.95. The die of claim 94, wherein an angle of the perimeter near a frontface of each plate in the die body is greater than an angle of theperimeter near a back face of an adjacent plate.
 96. The die of any ofclaims 92-95, wherein the stack includes a non-uniform die plate havinga bore perimeter angled at a first angle near a front face of the plateand angled at a different second angle near a rear face of the plate.97. The die of any of claims 92-96, wherein at least one of the dieplates is formed from two different materials, with a first materialforming a perimeter of a bore in the die plate and a second materialforming an outer portion of the die plate.
 98. The die of claim 97,wherein the first material is a ceramic material, a steel, or aconsumable material.
 99. The die of any of claims 85-98, wherein thebase comprises a circular bore having a diameter greater than thediameter of the exit of the die body.
 100. The die of any of claims85-99, further comprising a motor that supplies a rotational force tothe base.
 101. The die of any of claims 85-100, wherein a front face ofthe die body near the entrance is configured to mate with a centeringinsert having a diameter substantially equal to the diameter of theentrance.
 102. The die of claim 101, wherein the centering insert and aperimeter of the entrance are formed from the same material.
 103. Thedie of claim 101 or 102, wherein the centering insert does not rotatewhen the base and die body rotate.
 104. The die of claim 103, whereinthe centering insert comprises a gripper that prevents rotation of abillet passing through the centering insert. 105-124. (canceled)